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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10

Materials Analysis: A Key to Unlocking the Mystery of the Columbia Tragedy

Materials analyses of key forensic evidence helped unlock the mystery of the loss of space shuttle Columbia that disintegrated February 1, 2003 while returning from a 16-day research mission. Following an intensive four-month recovery effort by federal, state, and local emergency management and law officials, Columbia debris was collected, catalogued, and reassembled at the Kennedy Space Center. Engineers and scientists from the Materials and Processes (M&P) team formed by NASA supported Columbia reconstruction efforts, provided factual data through analysis, and conducted experiments to validate the root cause of the accident. Fracture surfaces and thermal effects of selected airframe debris were assessed, and process flows for both nondestructive and destructive sampling and evaluation of debris were developed. The team also assessed left hand (LH) airframe components that were believed to be associated with a structural breach of Columbia. Analytical data collected by the M&P team showed that a significant thermal event occurred at the left wing leading edge in the proximity of LH reinforced carbon carbon (RCC) panels 8 and 9. The analysis also showed exposure to temperatures in excess of 1,649 C, which would severely degrade the support structure, tiles, and RCC panel materials. The integrated failure analysis of wing leading edge debris and deposits strongly supported the hypothesis that a breach occurred at LH RCC panel 8.

Mayeaux, Brian M.↗

The Value of Workmanship Standards: What we Want, What we Ask For, What we Get

The Workmanship Standards serve to force positive outcomes rather than to depend only on finding and repairing defects. The Workmanship requirements address all avenues that can introduce defects or allow them to exist at the next level of integration: design, materials, processes, process control, screening.

Plante, Jeannette↗

Achieving ICME with Multiscale Modeling: The Effects of Constituent Properties and Processing on the Performance of Laminated Polymer Matrix Composite Structures

Integrated computational materials engineering (ICME) is a useful approach for tailoring the performance of a material. For fiber-reinforced composites, not only do the properties of the constituents of the composite affect the performance, but so does the architecture (or microstructure) of the constituents. The generalized method of cells is demonstrated to be a viable micromechanics tool for determining the effects of the microstructure on the performance of laminates. The micromechanics is used to predict the inputs for a macroscale model for a variety of different fiber volume fractions, and fiber architectures. Using this technique, the material performance can be tailored for specific applications by judicious selection of constituents, volume fraction, and architectural arrangement given a particular manufacturing scenario

computational mechanics↗

3D Printing Multi-Functionality: Embedded RF Antennas and Components

Significant research and press has recently focused on the fabrication freedom of Additive Manufacturing (AM) to create both conceptual models and final end-use products. This flexibility allows design modifications to be immediately reflected in 3D printed structures, creating new paradigms within the manufacturing process. 3D printed products will inevitably be fabricated locally, with unit-level customization, optimized to unique mission requirements. However, for the technology to be universally adopted, the processes must be enhanced to incorporate additional technologies; such as electronics, actuation, and electromagnetics. Recently, a novel 3D printing platform, Multi3D manufacturing, was funded by the presidential initiative for revitalizing manufacturing in the USA using 3D printing (America Makes - also known as the National Additive Manufacturing Innovation Institute). The Multi3D system specifically targets 3D printed electronics in arbitrary form; and building upon the potential of this system, this paper describes RF antennas and components fabricated through the integration of material extrusion 3D printing with embedded wire, mesh, and RF elements.

antennas↗

Portable Virtual Training Units

The Mission Operations Lab initiated a project to design, develop, deliver, test, and validate a unique training system for astronaut and ground support personnel. In an effort to keep training costs low, virtual training units (VTUs) have been designed based on images of actual hardware and manipulated by a touch screen style interface for ground support personnel training. This project helped modernized the training system and materials by integrating them with mobile devices for training when operators or crew are unavailable to physically train in the facility. This project also tested the concept of a handheld remote device to control integrated trainers using International Space Station (ISS) training simulators as a platform. The portable VTU can interface with the full-sized VTU, allowing a trainer co-located with a trainee to remotely manipulate a VTU and evaluate a trainee's response. This project helped determine if it is useful, cost effective, and beneficial for the instructor to have a portable handheld device to control the behavior of the models during training. This project has advanced NASA Marshall Space Flight Center's (MSFC's) VTU capabilities with modern and relevant technology to support space flight training needs of today and tomorrow.

Malone, Reagan↗

Technology Investments in the NASA Entry Systems Modeling Project

The Entry Systems Modeling (ESM) technology development project, initiated in 2012 under NASAs Game Changing Development (GCD) Program, is engaged in maturation of fundamental research developing aerosciences, materials, and integrated systems products for entry, descent, and landing(EDL)technologies [1]. To date, the ESM project has published over 200 papers in these areas, comprising the bulk of NASAs research program for EDL modeling. This presentation will provide an overview of the projects successes and challenges, and an assessment of future investments in EDL modeling and simulation relevant to NASAs mission

Barnhardt, Michael↗

Li-O2 Batteries for NASA Electric Aircraft (LiON)

Li-Air batteries are a unique fit for electric aircraft due to their high theoretical energy densities and their potential to leverage on-board oxygen systems. We will investigate novel "electrolyte engineering" concepts integrating computation, material fabrication and cell/pack design to obtain Li-Air batteries with high energy densities, rechargeability and safety.

Lawson, John↗

Intergenerational Inequities in Exposure to Climate Extremes: Young Generations Are Severely Threatened By Climate Change

Under continued global warming, extreme events such as heat waves will continue to rise in frequency, intensity, duration, and spatial extent over the next decades. Younger generations are therefore expected to face more such events across their lifetimes compared with older generations. This raises important issues of solidarity and fairness across generations that have fueled a surge of climate protests led by young people in recent years and that underpin issues of intergenerational equity raised in recent climate litigation. However, the standard scientific paradigm is to assess climate change in discrete time windows or at discrete levels of warming, a “period” approach that inhibits quantification of how much more extreme events a particular generation will experience over its lifetime compared with another. By developing a “cohort” perspective to quantify changes in lifetime exposure to climate extremes and compare across generations (see the first figure), we estimate that children born in 2020 will experience a two- to sevenfold increase in extreme events, particularly heat waves, compared with people born in 1960, under current climate policy pledges. Our results highlight a severe threat to the safety of young generations and call for drastic emission reductions to safeguard their future. Meteorological extremes, hazards, or climate change impacts are mostly studied as they evolve over time under varying emission scenarios and socioeconomic pathways. For example, applying a heat wave indicator (see table S1) to four bias-adjusted global climate models indicates that the land area annually affected by such heat waves will increase from ~15% around 2020 to ~22% by 2100 under a scenario compatible with limiting global warming to 1.5°C, and to ~46% under a scenario in line with current emission reduction pledges (see the first figure). Recent studies extended this approach, studying aspects of climate change as a function of global mean temperature (GMT) increments, highlighting the scenario-independence of several extreme event indicators but remaining, in essence, a comparison of time windows. By contrast, we performed a birth cohort analysis by combining a collection of multimodel extreme event projections with country-scale life expectancy information, gridded population data, and future global temperature trajectories from the Intergovernmental Panel on Climate Change (IPCC) Special Report on Global Warming of 1.5°C (see supplementary materials). By integrating the exposure of an average person in a country or region to extreme events across their lifetime, we encapsulate spatiotemporal changes in climate hazards, population density, cohort size, and life expectancy (see the first figure).

global warming↗

Topical. Permanent Low-Earth Orbit Testbed for Welding and Joining: A Path Forward for the Commercialization of Space

NASA, defense, academia, and commercial space companies seek to develop orbital manufacturing to enhance mission capabilities. In-space welding and joining are needed for space-based manufacturing. We propose a permanent low-earth orbital welding and joining testbed for scientific study of relevant physical phenomena and development of welding and joining processes to technical maturity. Such data will enable integrated computational materials engineering(ICME)to elucidate the underlying physical and metallurgical processes needed to achieve critical space welding and joining operations.

In-space manufacturing↗

A Robust Schema for Storing and Managing Machine Learning Data and Models

- Machine Learning (ML) has enabled models that can improve efficiency and decrease computational cost - ML models are crucial in enabling Integrated Computational Materials Engineering (ICME) - Large data sets require robust means of storing ML data and models

Brandon L. Hearley↗

Molecular Identification of Microbial Contaminants

Microorganisms can have significant impacts on the success of NASA’s missions, including the integrity of materials, the reliability of scientific results, and maintenance of crew health. Robust cleaning and sterilization protocols are currently in place in NASA facilities, but agency experts agree that microbial contamination is unavoidable and its impact on NASA’s missions and science must be minimized. Therefore, it is critical to understand: 1) what specific microorganisms are present, 2) how they may impact scientific objectives, and 3) how to select appropriate mitigation strategies. The Marshall Space Flight Center (MSFC) Planetary Protection (PP) microbiology lab historically relied solely upon enumeration of culturable microbial contamination associated with spacecraft materials or cleanrooms. However, this process is time consuming, many microbes cannot be cultured, and very few can be identified with any fidelity using NASA standard microbiological methods. The work described in this white paper includes the establishment of molecular identification capabilities at MSFC, including DNA isolation, amplification, purification, and Sanger sequencing. This capability will not only improve planetary protection efforts at MSFC (i.e. by identifying contaminating microorganisms in cleanrooms or on spacecraft) but also offers a service center-wide for the identification of contaminants that arise in other projects, processing locations, or during set up and roll out of spacecraft. This work also lays the foundation for higher throughput efforts to identify large populations of microbes across the lifetime of a project and serves as the starting point for future work into whole genome sequencing, non-culture based methods, or additional characterization studies. Ultimately, accurate identification informs appropriate mitigation strategies, increasing the chances of success for NASA’s missions and objectives.

C. D. Cassilly↗

Isolation, Identification, and Characterization of MSFC Cleanroom Microbes

Microorganisms can have significant impacts on the success of NASA’s missions, including the integrity of materials, the reliability of scientific results, and crew health. Robust cleaning and sterilization protocols are currently in place in NASA’s facilities, but microbial contamination is unavoidable and its impact on NASA’s missions and science must be minimized. Stringent cleaning and sterilization protocols are currently utilized by NASA, but many projects and materials have constraints on available sterilization procedures. Therefore, it is of utmost importance to be informed of: 1) what specific microorganisms are present, 2) how they may impact mission objectives, and 3) how to mitigate them.

Planetary Protection↗

LISA EDU Status

LISA will be the first space-based gravitational wave observatory, enabling orders of magnitude greater sensitivity than the state-of-the-art LIGO facility. L3Harris is developing an engineering development unit (EDU) telescope in support of NASA, ESA and the LISA Consortium. The LISA EDU telescope validates a flight-like telescope design and reduces risks associated with stability, materials, assembly, integration, and testing. Mission requirements are unlike any other and require picometer-level stability across the entire telescope’s beam path, even in the presence of temperature variation and jitter. As a result, an all-glass telescope design was developed. The brittle structure represents a new state of the art for stable telescopes, but also introduces challenges with managing assembly, manufacturability, and survivability. From 2019-2024, the LISA EDU project has increased manufacturing readiness and technology readiness for the optical telescope element.

Brian VanRensselaer↗

Maturation of In-space Welding in Reduced Gravity and Reduced Pressure Environments Through Progression to Suborbital Flight Experiments

Development of in-space welding (ISW) is a key and enabling manufacturing technology as welding is currently involved in producing approximately 90% of durable goods, and this trend is expected to hold for in-space manufacturing as well. ISW is critical to a sustainable space economy. To mature in-space welding, numerous gaps must be closed since NASA has not made a weld in space in 50 years. Advancing laser beam welding (LBW) towards a suborbital flight demonstration will help mature the process for in-space assembly & manufacturing (ISAM) through demonstration in relevant environments and achieving technology readiness milestones. LBW technologies and science improved by this work will benefit in-space manufacturing, long-term sustainability of space structures & operations, and the overall space economy. Ground-based welding of aerospace hardware requires an Edisonian approach to qualify a welding process; however, this approach is infeasible for ISW qualification due to mass, volume, logistic, and cost challenges inherent to the space environment. To address this challenge, we are conducting ground and suborbital tests with partners performing parabolic flights to gather data on LBW processes and infuse them into NASA & partner missions. This progression from ground to flight experiments will elucidate relevant physics during LBW: 1) reduced gravity, 2) reduced pressure, and 3) extreme temperature. Data from post-flight evaluation and in situ instrumentation will feed integrated computational materials engineering (ICME) tools to reduce the burden of ISW infusion by establishing a link between space and terrestrial environments, ultimately accelerating the qualification of LBW in space.

in-space welding↗

A Combined Computational, Experimental, and Technology Development Approach to In-Space Laser Manufacturing Maturation at NASA Marshall Space Flight Center

In-space manufacturing (ISM) is emerging as a field vital to continued access and capabilities in the space environment. NASA Marshall Space Flight Center (MSFC) is advancing the frontier of in-space laser manufacturing (ISLM) techniques through work initially focused on maturing laser beam welding (LBW) and laser forming (LF) for use in space. Such techniques proffer the ability to assemble and join structures in space from sheet metal or other stock – extant satellites, in situ resource utilization of Lunar regolith, etc. – by forming to desired shapes and then joining via in-space welding (ISW). ISLM processes are useful for assembly, joining, modification, and repair of structures in free space and on the Lunar surface such as large observatories, antennas, trusses, blast/thermal/radiation shields, pressure vessels, and more. However, these techniques are not yet qualified & certified (Q&C) for regular application in space. It would be prohibitively expensive, laborious, and time-consuming to perform Q&C via traditional experimental approaches as data collection & experimentation in space is resource-intensive. As such, benchmark experiments and focused, properly instrumented technology demonstration efforts in space can collect sufficient data that – when combined with verified computational models in an integrated computational materials engineering (ICME) approach – can validate ICME tools capable of translating more readily obtained ground data to in-space, in situ, computationally informed Q&C of ISLM techniques. Several ISLM projects at MSFC are obtaining the data required to validate ICME tools through both ground and flight experiments. A parabolic flight experiment of LBW under vacuum is manifested for August 2024, including both microgravity and Lunar gravity profiles. This collaboration with the Ohio State University is investigating common aerospace alloys such as 316L stainless steel, 2219 aluminum alloy, and Ti64 titanium alloy. In situ data collection includes videography, thermography, and reference thermocouples to build a thermal model of the welds. This will elucidate the relevant physics when combined with post-flight microstructural examination and mechanical testing. MSFC is also progressing towards a suborbital flight experiment of LBW under vacuum, which could provide reams of data on ISW during sustained, high-quality reduced gravity. The effect of combined thermal (cryogenic and high-temperature) and vacuum exposure on both LBW (NASA-funded) and LF (DARPA-funded) is being investigated through ground experiments. In addition to the copious data collected during these ground experiments, ruggedization of LBW hardware will also be pursued. The datasets from these experiments will be used to validate computational models which will inform future ISLM efforts in an ICME framework. A variety of techniques across lengths scales, from CALPHAD-driven thermodynamics & kinetics to phase field modeling of solidification to kinetic Monte Carlo simulations of grain evolution at the mesoscale, will be employed to accelerate the infusion and eventual Q&C of LBW and LF for use in space. The development of data-driven surrogate models to bridge ground to flight experiments and thereby reduce the need for resource-intensive experiments in space will also be investigated. These ICME techniques, surrogate models, and datasets from ground testing can also be employed to advance manufacturing in terrestrial environments.

in-space welding↗

Granular Material Scoop and Near-Vertical Lifting Feeder/Conveyor

An integrated granular-material scoop and near-vertical lifting feeder/conveyor includes special connections and skirts between a bullnose rotating scoop and an open-helical screw that provides the rotations and material lift and evacuation. A conical working-face of the bullnose rotating scoop has symmetrically distributed graters and vents to break loose and force-in granular material from natural deposits and cargo holds. The bullnose rotating scoop and the open-helical screw its attached to move the material into a continuous layer on the inside surface of an outer stationary sheathing. A motor drive attached to the open-helical screw above at the delivery end provides the lifting force necessary.

Walton, Otis↗

Joining and Integration of Silicon Carbide-Based Ceramic Materials for Aerospace Applications: An Overview

In order to fully utilize silicon carbide-based ceramics and ceramic matrix composites (CMCs) for aerospace and ground based applications, advanced joining and integration technologies are critically needed for achieving large, complex shaped, and integrated components. Careful material selection of joining inter-layers needs to consider chemical and thermal compatibilities with the parent materials that are being joined. Also, optimization needs to be conducted to select the proper processing conditions for achieving robust joints that are well adhered, strong, uniform, crack free, and have minimal residual stresses. NASA GRC developed pressureless and pressure aided approaches for joining ceramics and CMCs include brazing, diffusion bonding, refractory eutectic phase joining, and Single-step Elevated Temperature (SET) Joining. For joining ceramics and CMCs to metals, several brazes have been utilized. Brazing approaches for joining ceramics and metals have also included tailored brazes with multiple interlayers and particle additions. An overview of the joining approaches will be provided. In addition, processing-microstructure-property relationships will be discussed.

Silicon carbide↗

Heat Shield Employing Cured Thermal Protection Material Blocks Bonded in a Large-Cell Honeycomb Matrix

A document describes a new way to integrate thermal protection materials on external surfaces of vehicles that experience the severe heating environments of atmospheric entry from space. Cured blocks of thermal protection materials are bonded into a compatible, large-cell honeycomb matrix that can be applied on the external surfaces of the vehicles. The honeycomb matrix cell size, and corresponding thermal protection material block size, is envisioned to be between 1 and 4 in. (.2.5 and 10 cm) on a side, with a depth required to protect the vehicle. The cell wall thickness is thin, between 0.01 and 0.10 in. (.0.025 and 0.25 cm). A key feature is that the honeycomb matrix is attached to the vehicle fs unprotected external surface prior to insertion of the thermal protection material blocks. The attachment integrity of the honeycomb can then be confirmed over the full range of temperature and loads that the vehicle will experience. Another key feature of the innovation is the use of uniform-sized thermal protection material blocks. This feature allows for the mass production of these blocks at a size that is convenient for quality control inspection. The honeycomb that receives the blocks must have cells with a compatible set of internal dimensions. The innovation involves the use of a faceted subsurface under the honeycomb. This provides a predictable surface with perpendicular cell walls for the majority of the blocks. Some cells will have positive tapers to accommodate mitered joints between honeycomb panels on each facet of the subsurface. These tapered cells have dimensions that may fall within the boundaries of the uniform-sized blocks.

Zell, Peter↗